Preformed Niche Assembly

ABSTRACT

A preformed niche assembly and method of forming a niche include attaching the niche assembly in a stud cavity before a wall covering is installed. The preformed niche assembly includes a body that is constructed to be received in a stud cavity and a flange that extends about a perimeter of the body. The flange includes a first surface constructed to engage a stud and a second surface generally aligned with the first surface. The second surface of the flange is constructed to engage a non-exposed surface of a wall covering. The preformed niche assembly simplifies niche formation and allows positioning of a niche prior to installation of the wall covering.

BACKGROUND OF THE INVENTION

The present invention relates generally to preformed niche assembliesfor installation into walls, and more specifically, to a preformed nicheassembly that is constructed to be installed prior to installation of awall covering material, such as drywall.

A niche is generally understood as a recess or a cavity formed within awall surface. The niche is frequently used to provide an architecturaldetail to structures and/or provide storage or display recess within awall surface. Conventionally, the formation of such niches was a timeconsuming and labor intensive process. Generally, a carpenter wasrequired to rough frame a recess or cavity within a wall and a drywailer or plasterer was required to finish the surfaces and corners ofthe niche assembly. Understandably, the appearance of many such nichesrelied on the skill and ability of the tradesman forming such niches.More recently, preformed niche assemblies have been provided which areconfigured to be inserted into a wall cavity after the wall covering ispositioned thereon. Although such assemblies simplify the installationprocess, such configurations are not without their own drawbacks.

Commonly, such assemblies protrude beyond the wall surface and/orrequire the installation of complex trim assemblies in order to providea finished appearance to the niche. Another complication of such systemsis the ability to centrally locate such a niche within a wall cavity.That is, choosing a desired niche location that is not centrallydisposed within a stud cavity, presents the potential of severing thewall covering material across a stud surface only to discover that theniche cannot be installed in such a location. Another consideration ofsuch assemblies is the hidden potential of wiring and/or plumbing beingcontained within a desired wall cavity. The locations of such systemscan generally only ascertainable by forming an opening in the wallcovering and performing a visual inspection of the cavity therebehind.Only upon discovering such obstructions is it realized that the desiredniche location is unusable or useable only at considerable costassociated with moving the obstructing wiring or plumbing systems.Accordingly, such systems, although simplifying the niche assembly, donot necessarily simplify the installation of the niche.

Accordingly, it is desired to provide a niche assembly which canconveniently and efficiently be installed in a wall cavity prior toinstallation of the wall covering, wall board, or dry wall.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides a system and method of forming a nichethat overcomes the aforementioned drawbacks. A preformed niche assemblyaccording to one aspect of the invention includes a body that isconstructed to be received in a stud cavity and a flange that extendsabout a perimeter of the body. The flange is offset from a front face ofthe cavity and is constructed to be disposed between a stud and a wallcovering positioned over the stud. The niche includes a cutting guideconstructed to guide cutting of the wall covering to expose the body. Amud lip is formed proximate the cutting guide and is constructed toassist in the uniform application and finishing of a finish compoundsuch as drywall compound about the engagement between the wall coveringand the niche.

Another aspect of the invention includes a preformed niche assemblyhaving a body and a flange that extends from the body. The body isconstructed to be received in a stud cavity. The flange extendsgenerally about a perimeter of the body and has a first surface and asecond surface wherein the second surface is generally aligned with thefirst surface. The first surface is constructed to engage a stud and thesecond surface is constructed to engage a non-exposed surface of a wallcovering.

A further aspect of the invention discloses a preformed wall cavityhaving a back panel, a side panel, and a rib. The side panel extendsgenerally perpendicular from the back panel and the rib extendsgenerally perpendicular from the side panel. A groove is formed in therib proximate the side panel and is constructed to guide a cutter aboutthe side panel. Such a construction allows the preformed wall cavity tobe easily installed prior to installation of a wall covering or drywallmaterial.

Yet another aspect of the invention includes a method of forming a nichewhich includes the steps of forming a cavity constructed to be receivedin a stud space wherein the cavity is defined by an end panel and anupstanding side panel. The method further includes extending a flangefrom the cavity for engaging studs positioned on generally oppositesides of the stud space. The flange is offset from a front edge of theupstanding side panel for engaging the stud and a backside of awallboard. Such a construction allows the niche to guide installation ofdrywall around the niche.

These and various other features, aspects, and advantages of the presentinvention will be made apparent from the following detailed descriptionand the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate one preferred embodiment presently contemplatedfor carrying out the invention.

In the drawings:

FIG. 1 is a perspective view of a niche assembly according to thepresent invention installed in a wall;

FIG. 2 is an elevational view of the niche assembly shown in FIG. 1 witha wall covering removed from the area about the niche assembly;

FIG. 3 is a cross-sectional view of the niche assembly along line 2-2shown in FIG. 2 with a wall covering positioned over the niche assemblyand a cutting tool engaged with a guide of the niche;

FIG. 4 is a cross-sectional view of the niche assembly similar to FIG. 3with the wall covering engaged therewith; and

FIG. 5 is a detailed view of the finished installation of the nicheassembly along line 5-5 indicated in FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a preformed wall cavity or niche assembly 10 installed in awall 12. Niche assembly 10 includes a body 14 having an end or backpanel 16 and a side panel 18 that generally surrounds the back panel 16.Side panel 18 is constructed to extend generally perpendicular from backpanel 16 and extends between an exposed wall surface 20 and back panel16. Side panel 18 includes a bottom portion 22 that is orientedgenerally parallel to a floor 24. Side panel 18 includes an arcuate orcurved surface 26 configured to provide a more aesthetically pleasingniche assembly. Understandably, niche assembly 10 could be constructedto provide any shaped recess within a wall cavity. Niche assembly 10 isconstructed preferably of a plastic-type material and is constructed tobe paintable and/or to receive a dry wall compound thereacross.Frequently, many people prefer a texture sprayed wall finish or a skiptrowel type finish. Niche assembly 10 is constructed to accommodate anyof a number of wall finishes including those listed above as well assimply painting of the niche.

As shown in FIG. 2, niche assembly 10 includes a flange 28 constructedto extend from side panel 18. Flange 28 includes a number of holes 30constructed to allow passage of fasteners 32 therethrough. Fasteners 32pass through flange 28 of niche assembly 10 and engage wall materials orstuds 34. An optional horizontal brace 36 may extend between studs 34and provides additional support for bottom portion 22 of niche assembly10. As commonly understood, the distance between adjacent studs 34 iscommonly referred to as a stud cavity 38 and back panel 16 and sidepanel 16 are configured to fit within stud cavity 38. Accordingly, backpanel 16 and side panel 18 forms a cavity 40 that is constructed to beexposed when the wall surface is finished. A protrusion or mud lip 42extends about side panel 18 and provides an edge for wall finishing aswill be further described.

Flange 28 includes a cutting groove 44 that extends about cavity 40 ofniche assembly 10. Preferably, flange 28 is constructed to provide acutting guide associated with the installation of a wallboard or drywallabout the niche assembly 10. It is appreciated that niche assembly 10 beconfigured to fit within any desired stud cavity 38 and have any desiredshape and/or appearance.

As shown in FIG. 3, niche assembly 10 is constructed to be snugglypositioned within the stud cavity 38 associated with adjacent studs 34.Optional spacer blocks 46 may also be provided to prevent lateraltranslation of niche assembly 10 and ensure centered installation ofniche assembly 10 in the selected stud cavity 38. Back panel 16 isconstructed to be disposed against an unexposed surface 48 of a wallcovering 50 associated with an opposite side 52 of wall 12. Flanges 28extend from side panel 18 and include an S-shaped portion 54 constructedto provide an offset, as indicated by dimension 56, between a front edge58 of side panel 18 and a stud face 60. Preferably, offset 56 isslightly larger than a thickness, indicated by dimension 62, of wallcovering or dry wall 64. Understandably, offset 56 may be constructed toaccommodate a number of thicknesses 62 associated with different wallcovering materials.

During installation of dry wall 64, a cutter 66 is passed through drywall 64 and cuts the dry wall to expose cavity 40 of niche assembly 10.Flange 28 is constructed to guide operation of cutter 66 about nicheassembly 10 to allow for the efficient installation of drywall 64.Understandably, although cutter 66 is shown as a rotary cutting tool 68,other cutting tools, such as a dry wall knife, are envisioned andequally applicable to the present invention and operative with theguided cutting construction of niche assembly 10.

Referring to FIG. 4, after cutter 66 passes generally around a perimeterof the front edge 58 of niche assembly 10, that portion of dry wall 64not overlapping niche assembly 10 is allowed to move past front edge 58of niche assembly 10 toward flange 28 and stud face 60. A number offasteners 70 secure dry wall 64 to stud 34 such that drywall 64 issecured to studs 34 generally about niche assembly 10. Exposed surface72 of dry wall 64 is generally aligned with a land 74 of flange 28 andis offset slightly inward of mud lip 42.

As shown in FIG. 5, application of mud, plaster, or a dry wall compound76 provides a finished appearance of the transition between dry wall 64and niche assembly 10. Drywall compound 76 is introduced to groove 44and feathered between mud lip 42 and an extending wall portion 80. Suchan application provides a uniform transition between extending wallportion 80 and cavity 40 of niche assembly 10 and increases theengagement area of the drywall compound 76 with the interface betweenniche assembly 10 and extending wall portion 80. Such a configurationreduces the potential of the chipping, peeling, or cracking of compound76 cause by inadvertent impacts therewith.

Installation of niche assembly 10 prior to installation of dry wall 64prevents the installation of a niche assembly in a stud cavity that mayotherwise be occupied with electrical and/or plumbing connections.Furthermore, flange 28 and mud lip 42 provide for simple and generallycommon finishing of the connection between the niche assembly 10 and drywall 64. Furthermore, cutting guide 65 provides for efficientinstallation of the wall covering after the niche assembly 10 has beeninstalled within a stud cavity. Accordingly, niche assembly 10 providesa niche that is relatively easy to install and finish about as well asinexpensive to manufacture.

Therefore, one embodiment of the present invention includes a preformedniche assembly having a body and a flange that extends from the body.The body is constructed to be received in a stud cavity. The flangeextends generally about a perimeter of the body and has a first surfaceand a second surface that is generally aligned with the first surface.The first surface is constructed to engage a stud and the second surfaceis constructed to engage a non-exposed surface of a wall covering.

Another embodiment of the invention includes a preformed wall cavityhaving a back panel, a side panel, and a rib. The side panel extendsgenerally perpendicular from the back panel and the rib extendsgenerally perpendicular from the side panel. A groove is formed in therib proximate the side panel and is constructed to guide a cutter aboutthe side panel. Such a construction allows the preformed wall cavity tobe easily installed prior to installation of a wall covering or drywallmaterial.

A further embodiment of the invention includes a method of forming aniche, which includes the steps of forming a cavity constructed to bereceived in a stud space wherein the cavity is defined by an end paneland an upstanding side panel. The method further includes extending aflange from the cavity for engaging studs positioned on generallyopposite sides of the stud space. The flange is offset from a front edgeof the upstanding side panel for engaging the stud and a backside of awallboard. Such a construction allows the niche to guide installation ofdrywall around the niche.

The present invention has been described in terms of the preferredembodiment, and it is recognized that equivalents, alternatives, andmodifications, aside from those expressly stated, are possible andwithin the scope of the appending claims.

1. A preformed niche assembly comprising: a body constructed to bereceived in a stud cavity; a flange extending generally about aperimeter of the body and having a first surface and a second surfacegenerally aligned with the first surface; and wherein the first surfaceis constructed to engage a stud and the second surface is constructed toengage a non-exposed surface of a wall covering.
 2. The preformed nicheassembly of claim 1 further comprising a plurality of holes formed inthe flange.
 3. The preformed niche assembly of claim 1 furthercomprising a groove formed between the flange and the body for guiding acutter
 4. The preformed niche assembly of claim 1 wherein the flange isoffset from a front edge of the body a distance of approximately athickness of a desired wall board.
 5. The preformed niche assembly ofclaim 4 further comprising a lip formed at the front edge of the bodyand extending in a direction generally opposite a direction of theoffset.
 6. The preformed niche assembly of claim 1 wherein the body andflange are integrally formed of a plastic material.
 7. A preformed wallcavity comprising: a back panel; a side panel extending generallyperpendicular from the back panel; a rib extending generallyperpendicular from the side panel; and a groove formed in the ribproximate the side panel and constructed to guide a cutter about theside panel.
 8. The preformed wall cavity of claim 7 further comprising amud lip extending from the side panel in a direction generallyperpendicular to a direction of the rib from an edge of the side panelgenerally opposite the back panel.
 9. The preformed wall cavity of claim8 wherein the side panel and the mud lip has a length that is generallyequally to the sum of a stud depth plus a thickness of one wall coveringplus a joint compound thickness.
 10. The preformed wall cavity of claim7 formed of a plastic material.
 11. The preformed wall cavity of claim 7further comprising a plurality of nail holes formed in the rib forsecuring the wall cavity to a stud.
 12. The preformed wall cavity ofclaim 7 having a width approximately equal to a distance between anoutside surface of adjoining studs.
 13. The preformed wall cavity ofclaim 7 wherein the rib has a generally S-shaped cross-section.
 14. Thepreformed wall cavity of claim 7 wherein the rib has a portion thatextends in a first direction from a stud face and the groove extendsfrom the stud face in a second direction generally opposite the firstdirection.
 15. A method of forming a niche comprising: forming a cavityconstructed to be received in a stud space, the cavity being defined byan end panel and a upstanding side panel; extending a flange from thecavity for engaging studs positioned on generally opposite sides of thestud space; and offsetting the flange from a front edge of theupstanding side panel for engaging the stud and a backside of awallboard.
 16. The method of claim 15 further comprising forming acutting guide in the flange and extending the cutting guide about thecavity.
 17. The method of claim 15 further comprising forming the cavityand flange as a unitary assembly.
 18. The method of claim 15 furthercomprising forming at least one hole in the flange for receiving afastener to secure the flange to a stud.
 19. The method of claim 15further comprising forming a mud lip on the front edge of the upstandingside panel.
 20. The method of claim 15 further comprising forming theniche to receive a drywall compound over an exposed face of the cavityand an exposed portion of the flange.